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PLM World ‘06
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Digital Engineering Process at Isuzu
Author Yu (Fred) Homma / Naoki (Nick) NiiiCompany Isuzu Motors LimitedEmail [email protected]
[email protected] +81-466-45-9434
Index
· Company Outline & Products· Digital Engineering Concept· Achievement Summary· Next Step
· Establishment April 1937· Capital $283 M· President Yoshinori Ida· Sales $7,653 M· Employees 7,298· Major Product Trucks (H/M/L), Diesel Engines· Sales Units 233K units· Headquarters Oomori Tokyo· Assembly Plants Fujisawa, Kawasaki, Hokkaido, Poland, Ohio· Engineering Detroit, Bangkok· Office Gustavsburg
Company Outline & Products
1. Con-Current Development Engineering Intent Visualization DR by Experiments, ME, Service
2. Virtual Validation(VV) Validation before Real Proto Type Validate Vehicle variations
4. Shorten ME Activities ME Validation by 3D data
SOP
Experiments.
Imp.Design
CAPE
3DDesign
ProtRel.
CAE
DMUV
V
Prod.Rel.
StyleFreeze
ProtAssy
ME/Pilot/Production Preparation
V
V
3. Early BOMEarly Product data DefinitionSpeedy Information Delivery
Early BOM
Digital Engineering Concept
DR: Design Review
Achievement Summary
· Achievement in Virtual Validation· Product Data Management by TcAE· Process Management by CAE Gate· Knowledge Management by CAE Standard
& CAE Automation· Tool Management by CAE Utilization
& CAE Integration· User Management by CAE Skill Up Training
· Result at Current Project· In Process CAE at Current Project· Excellent Quality of the First Real Prototype
Product Data Management by TcAE
Layout
Drawing
Per formance
Assembly
Manual
Design (Alias) Process
Catalogue
Manufacture
Regulation
TcAE
· Virtual Validation(VV) around the TcAE
DR
DR TcAE
Layout
Engineer ing
TestCAE
ME
Engineer ingEngineer ingConceptualConceptual ValidationValidation ProtoReleaseProto
Release
Major Par tLayout
LayoutCr iter ia
QualityCr iter ia
Vir tualValidation
Repor tAnalysis
Impr ovement
DetailEngineer ing
CAEValidation
CounterMeasure
CAPEValidation
CAE Gate
Suppor t
Assist
Confir m
DR
Eng.Plan
L/OPlan
DetailLayout
LO;Layout DR;Design Review ECR;Eng. Change Request
AssemblyCr iter ia
TestPlan
Mfg.Plan
Manufactur ingjudge
Eng.Release
CADValidation
ECR
Process Management by CAE Gate
Knowledge Management by CAE Standard
· Bullet 1· Bullet 2Vibration
SafetyAirflow
ManufacturingDurability
Combustion
· Over 400 CAE Standards
CAE Automation using the CAE Standard
· Bullet 1· Bullet 2 NX Process Studio
Automated CAE ToolStructural Process Studio
CAE Exp.Dept.
Design Eng.Dept.
Beginner
Specialist
Simple CAE ToolNX Scenar io
Ear ly CAE & CAE Val.Apply CAE Stds.
CAE Tool for Specialist
CAE DevelopmentCreate CAE Stds.
CAE Tool for Specialist
Single PartSimple Load
Simple Condition
AssemblyComplicated Load
Complicated Constrains
Tool Management by CAE Utilization
Parts model Full model
Nastr anAbaqus
AdamsStarCD
LsDynaPatran
HyperMesh
I-deasEASi
Prostar
NX Environment
NX1
NX2
NX3
NX4
NX5
Try out CAEEase of use
Conceptual CAECAE StandardizeNew functionality
Try out CAEHigh end functionality
Evaluation CAEHigh end functionality
Assembly model
Integrating CAE
SOFY
NX6-10
Tool CAE Integration on NX Env.
CAE Exp.Dept.
Design Eng.Dept.
Beginner
Specialist
User Management by CAE Skill Up Training
· 700 NX Scenario Users*· Japan· Thailand· USA**· China**
Step1 -- Basic1. Virtual Development Process2. Application3. Theory4. Modeling5. Verification 6. CAE Standard7. Reporting
Step2 -- Operation
Certification
* 500 users so far** form now on
Step3 -- Enhancement Training (by correspondence)
In Process CAE at Current Project
· Meet the Capacity Request
· Meet the Lead Time Request
Num
ber o
f C
AE
Rep
orts
Month
Month
CA
E L
ead
Tim
e (h
r)
Average (hr)
Excellent Quality of the First Real Proto.
OK Ongoing NG
Handling/Comfort
12
Cooling
312
Idle Oscillation
33
Cab NVH/Acoustic
108 4
O/S mirror NV
3 3
Bumper Rigidity/Durability
25 3
Steering NV
14
Cab Rigidity/Durability
1854 1
Seat Rigidity/Durability
5723 12
Panel Rigidity
718 2
Door Rigidity/Durability
216 6
Cab Parts Rigidity/Durability
3356 8
RUP/FUP Regulation
169 3
Seat Belt Anchor Strength
1312
Drive-ability
31
Regulation
3
Fame Rigidity/Durability
754 3Suspension Rigidity/Durability
5517 3
Mount Rigidity/Durability
613 1
Mount Load
723 1
Chassis Parts NVH/Durability
416
Chassis Impact
45 2
Cab Crash
37 1
Frame NVH
11
Vehicle NVH
654%9%
37%
Aero Dynamics
6 6
Reduce Problem
· Front Loading by EDC· EDC:Engineering Design Communication· ECR:Engineering Change Request
Previous ProjectECR
Current ProjectECR
Current ProjectEDC
Next Step
· Expand the Virtual Validation· Increase Validation Items· Improvement Capability Level· Integrated System Level Analysis
· Automated Virtual Design· Optimization
Expand the Virtual Validation
· Integrated System Level Analysis
Proving Ground
Crash Laboratory
NVH
Aerodynamics
Cooling
Combustion
Piston/Crank Motion
Suspension Motion Heat Stress
Fatigue
Acoustic
Driver
Power Train Motion
Intake-port Flow
Automated Virtual Design
· Optimization
Shape Optimization
Topology Optimization
Topography Optimization
Morphing
Make Hole
Make Hole
Make Bead
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